DETAILED WET PROCESS OF CEMENT MANUFACTURING - LCETED

DETAILED WET PROCESS OF CEMENT MANUFACTURING - LCETED 

If the chalk is used in the wet process, it is finely broken and spread in water in the wash mill. The wash mill is a circular pit with rotating radial arms with rakes that break the solids into lumps. In a similar wash mill, the soil is also broken and mixed into the water. Now the two mixtures are pumped so that the mixture can be passed in a predetermined ratio and passed through a series of screens. The resulting cement slurry flows into storage tanks.

 

When limestone is used, the first blast it, then crush it into two progressively smaller crushers and then pour into a ball mill with clay dispersed in water. The resulting solution is pumped into storage tanks.

 

The slurry is a creamy consistency liquid with a water content of 35-50% and a fraction of the material approximately 2% larger than a 90μm sieve size. There are many storage tanks provided to store the slurry. Settling of suspended solids prevented by bubbling by compressed air or mechanical stirrers.

ALSO READ: DETAILED DRY PROCESS OF CEMENT MANUFACTURING - LCETED 

 

The slurry with the desired lime content is transferred to the rotary kiln. This is a large refractory-lined steel cylinder up to 8 m in diameter and sometimes 230 m in length. The steel cylinder rotates slowly around its axis and tilts slightly horizontally. The slurry is supplied to the kiln at the top, and the pulverized coal is blown by air blast at the bottom of the kiln at about 1450 °C. The coal used in the kiln should not have too high ash content, as 220 kg of coal is used to make 1 ton of cement. It is worth considering the amount of cement.

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The dry material goes through a series of chemical reactions in the hottest part of the kiln, about 20-30% of the material becomes liquid, and lime, silica and alumina are recombined. The fused mass turns the fuse into a ball with a diameter of 3 to 25 mm kn called as clinker. The clinker falls into a cooler that cools under controlled conditions. Cooled clinker and 3-5% of gypsum are crushed in a ball mill to the necessary fineness and then taken to storage silos, packed with cement.

 

The kiln must work continuously to ensure a steady regime and uniformity of the clinker. A conventional, larger kiln in a wet process plant produces 3600 tons of clinker per day.

 

Cement manufacturing by wet the process is energy-intensive, so it is uneconomical compared to dry process and semi-dry process.

ALSO READ: DETAILED MANUFACTURING PROCESS OF CEMENT

 

Advantages: The wet process of cement production has the characteristics of simple operation, low dust and easy transport. The slurry has good fluidity, good homogeneity, and the quality of the clinker is improved. In addition, the energy consumption of raw material grinding in wet processes is reduced by almost 30%.

 

Disadvantages: The heat consumption of the wet process is very high, generally between 5234-6490 J / kg and the consumption of the vulnerable areas of the ball mill is high. Compared with other processing methods, the clinker produced by the wet process has a lower temperature when leaving the kiln, so this method is not suitable for producing clinker with a higher silica rate and higher aluminium-oxygen.

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